Process of welding



L. B. BREWSTER AND F. WHSEHAN.

' PROCESS 0F WELDING.

APPLICATION FILED DEC. 7, 1911.

1,327,267, Batented Jan. 6, 1920.

Willi/A y////////'///////////- vention may be said to comprise the steps UNITED STATES PATENT oEEIoE.

LEON B. BREWSTER AND FRANK WEISEHAN, OF CLEVELAND, OHIO, ASSIGNORS T0 THE FERRO MACHINE AND FOUN'DRY COMPANY, 0F CLEVELAND, OHIO, CORPORATION 0F OHIO.

PROCESS OE WELDING.

Patented Jan. 6, 1920.

Application inea December?, 1917. serial No. 205,926.

To all 'whom 'it may concern;

Be it known that we, LEoN B. BREWSTER and FRANK WEISEHAN, citizens of the United States, and residents, respectlvely, of Cleveland, in'the county of Cuyahoga and State of Ohio, and Cleveland, in the county of Cuyahoga and State of Ohio, have 1nvented a certain new and useful Improvement in Processes of Welding, of whlch the following is a full, clear, and exact description.

This invention relates to a process or method by which one metal' may be deposited on another, and the deposited metal made to adhere to the metal on which 1t is deposited. K

The process is more particularly adapted and intended for use in the filling of cavities which may occur in castings or other metal objects. Generally speaking, the 1nin the process more particularly set forth in the claims.

Reference should be had to the accompanying drawings forming a. part of this specification, in which Flgure l illustrates an elevation and'more or less dlagrammatlc arrangement of a casting and apparatus for carrying out the invention; Fig. 2 1s a sectional elevation through the holder for the wire electrode.

The problem of depositing metal 1n cavities that may occur in castlngs of varlous metals, more particularlycast iron, due to a blow hole or sand flaw in the casting, has been a very vexing one. This has arisen n ot so much because of the difficulty of depositing metal in such a blow hole, but because of the fact that by such processes as have been tried, and in fact, by such processes with which we are familiar, the metal deposited is exceedinglyy hard, much harder than the metal of the body of the casting itself. Therefore, when the casting is ma: chned, the exceedingly hard spot of metal which has thus been deposited offers greater resistance to the cutting of aI cutting toolthan the surrounding metal, and the effect is that the cutting tool usually Jumps the hard spot of metal, thereby resulting 1n an imperfect machine.

Bythe process which Will be herein described metal may be deposited in such a cavity, caused to adhere to the metal upon which it is deposited aS by a weld, and the metal which is thus deposited is not hard and difficult to machine, but vwill be of a Y- hardness not greater than that of the metal of the body of the casting, and therefore when the casting is machined the cutting tool will operate upon the deposited metal the same as upon the metal of the casting itself.

Such an .apparatus as may be employed 1n carrying out the process, is illustrated in the drawing, in which 1 represents a casting containing a cavity which it is desired to lill with metal. The casting is mounted upon any suitable bench, but the casting should be insulated.

At 2 there is indicated a holder, preferably made of insulating material, or, in any event, care should be taken that the holder is insulated from the wire which is represented at 3. The holder is preferably a hollow holder, so that as the wire is consumed it may be fed through the holder and Secured therein.

The wire is secured to one terminal 4 of a circuit 4 5 and the other terminal 5 is secured to the casting in any suitable way, as by securing the wire 5 to a contact plate upon which the casting rests.-

The voltage and current supplied to the terminals 4-5 may be from any suitable source, and of course the current will be regulated as required.

At 7 a pipe is shown which has a restriction at one end thereof and at this end hydrogen gas is ignited. The member 7 is secured to a exible tube 8, which is in turn connected with the source of hydrogen.

In using the process, the hydrogen flame is held at the pointI or place Where the wire 3 is caused to contact at the casting.

In applying our process to `repairing a casting which has va blow hole in it, the blow hole is cleaned out so as to remove any sand or foreign matter. The casting is directly connected to one terminal of an electric circuit, while the other terminal of the electric circuit is formed by a metallic electrede, the metal of the electrode being fusible at the temperatures which are developed in the use of the electrode, and the metal furthermore being ductile.

The metal of the electrode is in wire form, the size of the wire used varying with the work which is to be done and the quantity of current which may be necessarily used in repairing the casting.

The current and the voltage of the current which is supplied. to the circuit may vary somewhat, but in the main will not exceed 16 volts and approximately 100 amperes. This current, it will be seen, is a, comparatively low current.

In carrying out the process the metallic electrode with the circuit in propel' condition is introduced to the bottom of the blow hole in the casting. As the metallic electrode contacts with the bottom of the blow hole, there is a moreor less imperfect contact, and the circuit which is thus closed by the Contact will therefore have avery high heating effect. This heating effect is localized, being confined to the end of the metallic electrode, and that portion of the easting which is adjacent the end of the metallic electrode. The contact of the electrode with the casting is maintained until the rise of temperature is sufficient to melt the end of the electrode, which will, of course, cause the metal thus melted to flow onto the casting and there takes place a welding action between the metal which is thus melted and that portion of the cavity of the casting which has been contacted by the electrode.

The actual time required to cause the melting and deposition of the metal is very short and requires but a momentary contact.

As Soon as this has taken place, the electrode is removed, thus breaking the circuit, and care must be taken that some degree of skill is required to remove the electrode at the proper time, in order thatl undue quantities of the electrode may not be removed or melted away.

The electrode is moved from spot to spot in the cavity and the foregoing operation repeated until the surface of the blow hole is covered by a deposit of the metal of the electrode. It will thus be seen that the surface of the blow hole is covered by a number ofi small particles of the metal of the electrode', all of which particles are welded to the particular portion of the surface of the blow hole with which the electrode contacted.

Due to the fact that the voltage and eurrent used are of low value, the metal which is thus deposited has caused a heating of that portion of the cavity only, which was contacted by the electrode.

The metal thus deposited is ductile and when once deposited a peening hammer is employed to peen the metal which has been introduced int-o the blow hole, thus causing the metal to be compacted, and any inequalities in the surface of the metal reduced.

The operation before described is repeated and this repetition causes a further amount of metal to be welded to the metal previously deposited in the blow hole. Themetal thus deposited is again subjected to a peening and the alternate process of dcpositing the metal and peening is continued until the proper amount of metal has been deposited in the blow hole to complet-ely lill and perchance a little more than fill the cavity of the casting.

By following the process which has been described, the metal thus deposited is not hard, but is comparatively soft, that is to say, it is at least assoft as the metal of' the casting itself, so that upon the machining of the casting the metal which has been deposited maybe removed in the machining action with the same facility as the metal of the casting.

The foregoing process --has been used with considerable success for the purpose ,-of lilling blow holes in engine cylinder castingsl which may develop when the engine cylinder is machined. Any blow hole developed under such conditions may readily be filled by following out the. foregoing process, and if, as before stated, the engine cylinder hasbeen machined, the excess metal which may be deposited by the process described mav be removed by a suitable tool, such as a tile..

ltis important to distinguish the process which has been described from that process by which metal from a fusible electrode is deposited upon other metal while maintainmg an arc between the metal electrode and the metal object upon which the metal from the electrode is to be deposited.

Metal which is thus deposited from a fusible electrode is exceedingly hard, and renders it quite impossible to satisfactorily machine a casting which has thus been repaired.

1n the process before discussed the metal is not deposited by virtue of metal which may be carried over from the electrode to the casting in the arc stream, but on the contrary, the heat which is developed for the purpose of depositing metal from the electrode is purely a heat generated by resistance and the electrode is removed when the proper heating effect has been obtained. In carrying out the foregoing process it is highly desirable to cause the deposition of the metal from the electrode under conditions which will insure against oxidation of the molten metal. This we have satisfactorily accomplished by maintaining a. reducing atmosphere at the place where the electrode. is touching the casting. In practice we have found a burning hydrogen atmosphere to be very satisfactory, and for this purpose we utilize a small hydrogen burner which is held in one hand of the operator in proper position While the other hand of the operator manipulates the fusible electrode.

Having thus described our invention, what We claim is: 1. The process of depositing metal from a fusible electrode having a high ltemperature point of fusion upon a body of metal having a high temperature point of fusion which consists in making the metal.to receive the deposited metal one terminal of a'circuit, and a fusible electrode another terminal of the circuit, bringing the fusible electrode into contact with the said metal object and holding the same in contact until the heat generated by the resistance of the current passing from the electrode to the metal ob]ect causes a heating and fusion of that portion of the metal object which is directly adjacent the electrode and causes a portion of the electrode to Vbe melted and Welded to the metal object and then removing the electrode.

2. The process of depositing metal from a fusible electrode upon a metal obj ect which consists in making the metal object one terminal of an electric circuit and the fusible electrode another terminal of said electric circuit, causing the fusible electrode to con-,i

a fusible electrode having a high`temperature point of fusion upon a metal object also having a high temperature point of fusion which consists in making the metal object one terminal of an electric circuit and the fusible electrode the other terminal of the circuit, supplying to said circuit a current which is of low volta-ge and current value, causing the fusible electrode to contact with the metal object thereby causing the metal object to be heated at the point of contact by the resistance of the current due to the Contact of the electrode with the metal object, and maintaining such contact until the metal object at the point adjacent the electrode is suiiciently heated and fused and metal from the electrode is melted to secure a welding action, and then removing the electrode.v

4. The process of depositing metal from the fusible electrode in a cavity of a metal object, which consists in making the metal object one terminal of an electric circuit, and a fusible electrode the other terminal of the circuit, bringing the nretal electrode into contact with a portion of the cavity thereby heating that portion of the metal object with Wluch the electrode is in contact, continuing such contact until the heat developed at the point of the metal object which is contacted is suiicient to cause a welding action between that point of the metal object and metal which is melted at the end of the fusible electrode, repeating such action until the surface of the cavity is covered by deposits ofmetal, peening the metal which has thus been deposited, subsevque'itly depositing additional metal upon the peencd metal and in continuing such operations until the cavity is filled.

In testimony whereof, We hereunto affix our signatures.

LEON B. BREWSTER. FRANK WE'ISEHAN. 

